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M02S08CourseNotes

The document outlines the rules of engagement for a three-day simulation involving assembly stations, inspection, and shipping processes. Operators are required to build in batches of five, maintain a steady workflow, and follow specific procedures for setups and quality control. A practice run with two airplanes is planned to familiarize participants with the process.

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2 views

M02S08CourseNotes

The document outlines the rules of engagement for a three-day simulation involving assembly stations, inspection, and shipping processes. Operators are required to build in batches of five, maintain a steady workflow, and follow specific procedures for setups and quality control. A practice run with two airplanes is planned to familiarize participants with the process.

Uploaded by

asad
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Module 02 – Section 08 Rules of Engagement

Now let’s get familiar with the rules of engagement for Day 1.

This simulation will have resources that will remain the same for the next three days. Workstations 1 thru
4 are assembly stations. We have one operator for each of these stations. At workstation 3, we have a
need for a setup. Workstation 5 is an inspection station. We have one inspector at this station.
Workstation 6 is for shipping, teardown and recording and we have an operator there recording the
information. We also have two industrial engineers. They are calculating the cycle time and lead time
through the process. These engineers are using a stop watch to make this calculation happen.

Next, let’s take a look at what is going to happen on day one. We build in batches of 5. The reason for
this is because our computers determined the EOQ is five. With that number, we hope our cost per unit is
less. Batches must remain together through to final inspection. This means that the product must be
built and transported from one station to the other, right through to workstation 5, then delivered to
workstation 6 for delivery.
Operators themselves must deliver the batches to the next operation. They cannot move the planes
across the table because this is a safety concern. They have to get up out of the chair and deliver the
product to the next station. That means workstation 1 must get up out of the chair and deliver in batches
of 5 into the queue of workstation 2 and so on.

Course notes, Lean 101, Module 2 Section 8


http://www.lean101.ca
Operators must procure their own parts. When they run out of parts, they must go to material stores and
bring them back to their stations. Operators must maintain a steady state of construction. That means
after an operator delivers their five planes to the next work station sit down and keep on producing. We
pay them to work, by the way.

At station 3 a set up is required; we also call this a changeover. We try to do this very consistently each
time so that the quality of the product remains the same. We need to go through a standard operating
procedure with very specific rules on setup so that the time is taken into account as well as the quality of
the product each time.
The inspector must identify quality problems and set the planes aside. They cannot communicate with the
rest of the plant and of course, that’s not unusual is it?
At station 6, the operator does shipping, tear down and recording. That operator considers the product
shipped at that point in time. They record the information needed for production numbers at the end of
the day. This feedback is given to production to indicate how well they have done.

All right now. Let’s begin by starting the simulation with a practice run. We are going to let everybody run
a batch of two airplanes down the assembly line so that everybody gets used to the process.

Course notes, Lean 101, Module 2 Section 8


http://www.lean101.ca

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